Building a

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Building a
Fall Protection Program
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Why Use Fall Protection?
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In 1995, 1,048 construction workers died on the
job, with 32, or 335 of them, resulting from
falls. Each year, falls consistently account for
the greatest number of fatalities in the
construction industry, and are always a major
concern in other industries. Events surrounding
these types of accidents often involve a number
of factors, including unstable working surfaces,
misuse of fall protection equipment, and human
error. Studies have shown that the use of
guardrails, fall arrest systems, safety nets,
covers, and travel restriction systems can
prevent many deaths and injuries from falls.
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Why Use Fall Protection?

• Falls are the 2nd leading cause of death in
  industry.
• Navy statistics of falls demonstrate falls
  actually do occur!
• Required By Federal Law!
• 29 CFR 1910, 1915 or 1926

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CNO N45 Fall Statistics FY 96 through FY 99
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CNO N45 Fall Statistics FY 96 through FY 99
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Types Of Fall Protection

• Traditional
• Standard Guardrails
• Ladder Cages
• Hand rails
• Scaffolding
• Lifelines

• Non Traditional
• Safety Harnesses
• Lanyards
• Carabiners
• Self Retracting Lifelines
• Tie-Off Adapters

Common to both methods An Engaged Brain is
required
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Program Elements

• Hazard Analysis
• Equipment
• Policy
• Training
• Inspection
• Rescue

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Hazard Analysis
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What Equipment And Conditions Do You Already Have!

• Quantify Exposure
• Tasks?
• Hazard?
• How controlled?
• Is the Hazard Unique?

• Qualify Equipment?
• Condition?
• Controls?
• Usability?

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Are The Fall Hazards Controlled With Adequate
Equipment For The Tasks Performed?
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Identify the Tasks

• Those That Do The Work Know the Tasks!
• ASK Them!!!

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WHERE SHOPS USE FALL PROTECTION EQUIPMENT

• When working 5 feet or more above a level surface
• Pulling shafts, screws(props),rudders, fairplanes
• On top of Conex boxes or portable buildings w/o
  life lines
• Working on Submarine Enclosure roofs
• Rigging Hull sections
• Working on Hull sections

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WHERE SHOPS USE FALL PROTECTION EQUIPMENT

• Rigging machinery pier side, on trailers and in
  railcars
• Attaching rigging to staging above 5 feet
• Staging work above 5 feet
• Removing/installing masts, antennas, waveguide,
  etc.
• Working on hulls w/ missing deck sections no
  guard rails

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WHERE SHOPS USE FALL PROTECTION EQUIPMENT (CONT.)

• Working from crane suspended box or basket/cage,
  or JLG
• Working in tanks
• Working aboard vessels in tall compartments
  (Includes multi-deck shafts, high vertical
  ladders, deck edge elevators, hangar deck
  overheads, machinery space upper levels, etc.)

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WHERE SHOPS USE FALL PROTECTION EQUIPMENT (CONT.)

• Rigging newly manufactured barge sections
• Installing tarps on roofs, tall structures,
  equipment, etc.
• Rigging sub roofs
• Working on cranes (indoors and outdoors)

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When should you use fall protection? Click on
the correct answer button
1. When working 5 feet or more above a level
surface.
2. Working on cranes (indoors and outdoors).
3. On top of Conex boxes or portable buildings
4. Working from crane suspended box or basket/cage
5. All of the above
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Determine What Equipment is Currently Available
at Your Facility.
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Quantity and Quality of Equipment

• 1693 Safety Belts ( 1094 c/o)
• 329 Harnesses (111 c/o)
• 787 Shock absorbing lanyards (324 c/o)
• 1424 Lanyards w/o Shock Absorber (995 c/o)
• No inspection criteria
• No maintenance criteria
• Majority of labels not legible
• No major replacement in 15 years

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Survey the Work Force

• Use a Few Simple Questions Designed to Identify
• Exposure to fall hazards.
• Effectiveness of current equipment.
• Survey can also collect data on the stature of
  the work force.

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Results of Hazard Analysis

• Exposure to the Fall Hazards!
• The Quality of the Hazard Control.
• Suitability of Equipment.
• The probability of occurrence and the extent of
  regulatory compliance can be estimated.
• Use The Hazard Analysis To Determine Extent of
  Remaining Program Elements.

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What information should your Hazard Analysis
provide?
The probability of occurrence and the extent of
regulatory compliance
Exposure to fall hazards.
Data on the stature of the work force

• Inspection criteria, Maintenance criteria

None of the Above
All of the Above
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Equipment Selection
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The Equipment

• Safety Harness
• Lanyards
• Heat Resistance Equipment

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The Equipment

• SRLs
• Rope Grabs
• Horizontal Lifelines
• Ladder Climbing Devices
• Beamers
• Special Devices

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Equipment Selection

• Evaluate each task individually.
• Determine what equipment meets the need.
• Become the expert cause no one else is.
• Look for equipment that matches multiple tasks.
• Use all sources available to you.
• Vendors
• Federal Stock System
• Manufacturers
• Trade Shows
• The Workers You are Trying to Protect

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Body harnesses OSHA Standard 1926.502(d)(18)
Body harnesses are designed to minimize stress
forces on an employee's body in the event of a
fall, while providing sufficient freedom of
movement to allow work to be performed. Do not
use body harnesses to hoist materials.
As of January 1, 1998, body belts are not
acceptable as part of a personal fall arrest
system, because they impose a danger of internal
injuries when stopping a fall.
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• Attachment of the body harness
• OSHA Standard 1926.502(d)(17)

The attachment of the body harness must be
located in the center of the wearer's back, near
the shoulder level, or above the head.
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Vertical Lifelines/Lanyards
Self-retracting vertical lifelines and lanyards
that automatically limit free fall distance to 2
feet or less must be capable of sustaining a
minimum tensile load of 3,000 pounds when in the
fully extended position. If they do not
automatically limit the free fall to 2 feet or
less, ripstitch lanyards, and tearing and
deforming lanyards, must be capable of sustaining
a minimum tensile load of 5,000 pounds when in
the fully extended position.
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• Webbing
• OSHA Standard 1926.502(d)(14)

Webbing are the ropes and straps used in
lifelines, lanyards, and strength components of
body harnesses. The webbing must be made from
synthetic fibers.
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• Anchorages
• OSHA Standard1926.502(d)(15)

Anchorages used for attachment of personal fall
arrest equipment must be independent of any
anchorage being used to support or suspend
platforms, and capable of supporting at least
5,000 pounds per employee attached.
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• Horizontal
• Lifelines/Lanyards
•  OSHA Standard 1926.451(g)(3)(ii)
• OSHA Standard 1926.451(g)(3)(iii)
• OSHA Standard 1926.502(d)(7)
• OSHA Standard 1926.502(d)(8)

Horizontal lifelines are to be designed,
installed, and used under the supervision of a
qualified person, and as part of a complete
personal fall arrest system which maintains a
safety factor of at least two. On suspended
scaffolds or similar working platforms with
horizontal lifelines that may become vertical
lifelines, the devices used to connect to a
horizontal lifeline must be capable of locking in
both directions on the lifeline.
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• Connectors
• OSHA Standard 1926.502(d)(1)
•  

Connectors, including D-rings and snaphooks, must
be made from drop-forged, pressed or formed
steel, or equivalent materials. They must have a
corrosion-resistant finish, with smooth surfaces
and edges to prevent damage to connecting parts
of the system.
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D-Rings
D-Rings must have a minimum tensile strength of
5,000 pounds, and be proof-tested to a minimum
tensile load of 3,600 pounds without cracking,
breaking, or becoming permanently deformed.
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Snaphooks
Snaphooks must have a minimum tensile strength of
5,000 pounds, and be proof-tested to a minimum
tensile load of 3,600 pounds without cracking,
breaking, or becoming permanently deformed.  They
must also be locking-type, double-locking,
designed and used to prevent the disengagement of
the snaphook by the contact of the snaphook
keeper with the connected member.
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Snaphooks

• Unless it is designed for the following
  connections, snaphooks must not be engaged
• Directly to webbing, rope, or wire.
• To each other.
• To a D-ring to which another snaphook or other
  connector is attached.
• To a horizontal lifeline.
• To any object which is incompatibly shaped in
  relation to the snaphook such that the connected
  object could depress the snaphook keeper and
  release itself.

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• OSHA Standard 1926.502(d)(9)

• Vertical lifelines or lanyards must have a
  minimum breaking strength of 5,000 pounds, and be
  protected against being cut or abraded. Each
  employee must be attached to a separate vertical
  lifeline, except during the construction of
  elevator shafts, where two employees may be
  attached to the same lifeline in the hoistway,
  provided
• Both employees are working atop a false car that
  is equipped with guardrails.
• The strength of the lifeline is 10,000 pounds
  (5,000 pounds per employee).
• All other lifeline criteria have been met.

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Involve the Organizations That Use It!

• What Fall Protection Equipment do Shops need to
  support the tasks identified?
• Typical Answer (universal response)
• Safety Belt and Lanyard, or
• Fall Protection Is Not Possible !

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Now You Know

• What the specific tasks are where employees are
  exposed.
• What equipment is suitable to abate the Hazard.

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Which types are correct examples of Fall Arrest
system equipment ?
Body Harnesses, body belt, vertical lifeline,
lanyards, anchor points, lifelines, d-rings.
Body Harnesses, snap rings, vertical lifeline,
lanyards, anchor points, horizontal lifelines,
d-rings, webbing.
Body Harnesses, snap rings, vertical lifeline,
lanyards, anchor points, webbing, horizontal
lifelines, d-rings, body belt.
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Self-retracting vertical lifelines which
automatically limit free fall distances have what
limits placed on them?
3 feet or less free fall, and 2000 pounds
2 feet or less free fall, and 5000 pounds
1 foot or less free fall, and 2000 pounds
4 feet or less free fall, and 5000 pounds
2 feet or less free fall, and 3000 pounds
None of the above
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Which is the correct anchorage point to use in
the following situation?
Three workers are working on a roof, and have one
anchor point to use between them. The anchor
point has been tested to 1485 pounds support. The
workers weigh 185, 192, and 155.
All three workers may tie off at the anchor
point, because of their 532 pound combined
weight.
There is no need to tie off, because they are on
a roof.
Only workers 1 and 3 may tie off because of their
combined weight.
Only 2 workers may tie off because you require at
least 5000 pounds per employee attached.
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D-Rings and Snap hooks must meet which of the
following requirements.
Made from drop-forged, pressed or formed steel,
or equivalent materials. They must have a
corrosion-resistant finish, with smooth surfaces
and edges to prevent damage to connecting parts
of the system and have a minimum tensile strength
of 3,000 pounds, and be proof-tested to a minimum
tensile load of 2,600 pounds without cracking,
breaking, or becoming permanently deformed
Made from drop-forged, pressed or formed steel,
or equivalent materials. They must have a
corrosion-resistant finish, with smooth surfaces
and edges to prevent damage to connecting parts
of the system and have a minimum tensile strength
of 5,000 pounds, and be proof-tested to a minimum
tensile load of 3,600 pounds without cracking,
breaking, or becoming permanently deformed
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Qualified Person

• One with a recognized degree or certificate and
  with extensive knowledge and experience, capable
  of evaluating and developing the design,
  analysis, specifications, associated with the
  components of a Personal Fall Arrest System.

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Competent Person

• One capable of identifying hazards associated
  with the use of Personal Fall Arrest Systems and
  the authority to take prompt corrective measure
  to eliminate hazards.

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Qualified / Competent Person
Read more about Qualified / Competent Person by
clicking below.
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Policy
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Building a Policy

• Must include applicable regulatory requirements.
• Must be simple and understandable.
• AND

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Building a Policy

• Must apply each of the tasks identified.
• Must be universal within your activity.
• Must be reasonable!
• AND

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Must be Possible!

• With the equipment you identify.

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A Policy

• WHEN IS FALL PROTECTION REQUIRED?
• Specific Situations
• Aerial Work Platforms, (JLGs, Scissor Lifts)
• Ladders with Ladder Climbing Devices
• Crane Suspended Personnel Platforms

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Policy (continued)

• Rule 1 When working at heights greater than
  five feet and not protected by a standard
  guardrail.
• Work excluded from this rule
• Working from a sloping ladder (step ladder or
  extension ladder).
• Climbing a fixed ladder that does not have a
  ladder climbing device.
• Personnel erecting or dismantling staging (when
  tie-off points are not achievable).

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Policy (continued)

• Rule 2 There is no minimum job duration allowed
  which excludes the fall protection requirement.
• If a two-minute job requires 15 minutes to
  establish fall protection, then spend the 15
  minutes!
• Exclusion 1st Person Up Rule If a fall
  protection anchorage point has not previously
  been established, the first job of the first
  person exposed to the fall hazard is to establish
  fall protection for themselves, and all persons
  that follow.

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Policy (continued)

• Rule 3 There is no minimum acceptable distance
  from an unguarded edge.
• Warning systems and Safety Monitors are not
  allowed.
• A physical barrier, such as rope, chain, closed
  hatch, or closed door, which prevents employees
  from approaching an unguarded edge is
  acceptable. Barrier tape is not considered a
  physical barrier.
• Unguarded Edge Edge with a fall hazard greater
  than 5 feet, not guarded by a standard guardrail
  or a parapet at least 34 inches high.

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Policy (continued)

• Areas excluded from Rule 3 Piers, Quay walls,
  Flooded Dry Docks - LIFE RINGS ARE STAGED and PFD
  requirements apply. However, working at the edge
  of a pier, quay wall, or flooded drydock five
  feet or more above a solid surface, (e.g., camel,
  barge, ice), requires fall protection.
• Note U-Bars placed at Submarine hatches,
  Shipboard accesses to tanks, voids, and similar
  areas are acceptable by OSHA interpretation
  (These are Ships equipment items).
• Note When working on flat roofs of permanent
  buildings that have unguarded edges, employees
  must have fall protection equipment on site and
  utilize the equipment when near an unguarded
  edge. Pitched roofs (pitch greater than 4
  inches) with unguarded edges require fall
  protection at all times.

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What 3 rules should you base your policy on?
When working at heights greater than five feet
and not protected by a standard guardrail there
is no minimum job duration allowed which excludes
the fall protection requirement there is no
minimum acceptable distance from an unguarded
edge.
When working at heights greater than seven feet
on any platform, including ladders any job 10
minutes or less excludes the fall protection
requirement minimum acceptable distance from an
unguarded edge is 1 foot, if you are farther than
1 foot from a edge, no fall protection is
required.
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Training
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Training

• Required by OSHA
• Required by ANSI Z359.1
• Required by all reasonable Competent Persons.
• HOW MUCH TRAINING IS ENOUGH?

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Typical Training Formats

• 2-8 hrs Familiarization
• 8 hrs Fall Protection for Managers/Engineers
• 8-16 hrs Full User Certification.
• 5 Days Competent Person Certification
• 8 - 10 Days Qualified Person Certification
• 10 - 12 Days Trainer Certification

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Users Course

• In-House Training
• Can Be Very Equipment Specific
• Shorter Training Times
• Least Effective
• More training required if equipment changes
• Commercial Courses
• Usually, the Best Overall Training
• Typically Includes Extraneous Information
• Expensive

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For the Competent Person,Qualified Person,and
Train the Trainer.
Use External Training Sources NAVOSHENVTRACEN
Course A-493-0084 for Competent Person
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Who Should Be Trained

• Each User,
• Supervisors and Work Leaders
• Suitable Number of Technical/Spec Writers
• The Competent Person
• Additional personnel, as needed
• Qualify at Least One Engineer as a Qualified
  Person
• Or get access to one, you will need them!

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Training
Each User, Supervisors and Work Leaders, Suitable
Number of Technical/Spec Writers, The Competent
Person, at Least One Engineer.
Safety Manager, All Supervisors and Work Leaders,
safety inspectors, The Competent Person, at Least
One Engineer, Commanding Officer or executive
officer.
Safety advisor, All new personnel arriving
onboard, All planners and designers, the
contracting authority.
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Inspection
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Pre-Use Inspection

• Each User Needs to Be to Be Trained to Perform
• Webbing
• Stitching
• Metal Components
• Overall Condition
• Detailed Inspection Documentation.

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Periodic Inspection

• Typically Interpreted as Annual
• Performed by the Competent Person
• Or by instruction from the Competent Person
• Detailed, documented, traceable component by
  component.
• Most manufacturers have guidelines.
• Specialized equipment must be returned to the
  manufacturer for this inspection.

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Who must perform inspections inspections?
Safety Manager
Subject matter expert
Competent Person
Fall protection program manager
Workcenter supervisor
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Rescue
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• People That Use Fall Protection Equipment Fall
  More Often Than People That Dont!
• A Means of Rescuing an Individual, suspended
  after a fall is
• Absolutely Crucial!

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Self Rescue

• Users must be trained in what they can do to
  rescue themselves
• and
• WHAT THEY, AND OTHER EMPLOYEES MUST NOT DO!

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Rescue Team

• Highly Specialized
• Beyond Knowledge of Competent and Qualified
• Emergency Personnel Usually Considered the Source
• DO NOT ASSUME YOUR FIRE DEPARTMENT IS TRAINED AND
  CAPABLE OF THIS FUNCTION!
• VERIFY!

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A Few Things to Worry About
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Anchorage Points

• Will They Fail During a Fall?
• Should they be
• Certified and Designated?
• or Improvised?
• How much is 5000 pounds?

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Free Fall Distance

• How Far Can You Fall and be Safe
• 4 Feet? (29 CFR 1910)
• 5 Feet? (29 CFR 1915)
• 6 Feet? (29 CFR 1910)
• (29 CFR 1915)
• (ANSI Z359.1)
• 8 Feet? (29 CFR 1926)

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Maximum Arresting Force (MAF)

• By OSHA and ANSI 1800 pounds.
• Injury Threshold 2700 pounds.
• Based upon medical research in France and U.S.
• Comparison
• Opening a parachute
• after free fall
  2250 pounds
• 30 MPH head on car crash
• into a test barrier with a 3
• point safety belt
  3000-6000 pounds

Fundamentals of Fall Protection Andrew C.
Sulowki 1991
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(No Transcript)
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Total Fall Distance

• Free Fall Distance
• Shock Absorber Length
• Body Length
• Stretch

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Pendulum Effect

• The velocity developed during a Vertical Free
  Fall can be translated into a horizontal
  velocity.
• Hitting a vertical wall with 800 pounds of force
  is same as hitting the floor with 800 pounds of
  force.

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Rescue Time

• After approximately 30 minutes of suspension,
  physiological effects become significant.
• Actual time depends upon age, health,physical
  condition and sex of individual.

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Safety Factors for the Program Manager
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Safety Factor to Injury

• Injury Force 2700 pounds
• Regulated MAF 1800 pounds
• Actual Arresting Force 800-900 pounds
• Regulated Safety Factor 1.5 1
• Actual Safety Factor 3 1
• Equipment and Individual dependent

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Single Point Improvised Anchorage

• Capable of Supporting 5000 pounds without
  failure.
• 1800 Pounds Maximum Arresting Force
• 800 - 900 Pounds typical Actual Arresting Force
• Regulated Safety Factor - 2.7 1
• Actual Safety Factor - 5.5 1
• Equipment Specific

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Engineered Single Point Anchorage

• Capable of supporting 3600 pounds without failure
• Regulated MAF 1800 pounds
• Actual Arresting Force 800 - 900
• Regulated Safety Factor 2 1
• Actual Safety Factor 4 1

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Engineered Personal Fall Arrest Systems (PFAS)

• Regulated Safety Factor of 2
• Actual Safety Factor - Engineer Dependent
• Example Horizontal Lifelines

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Scaffolding
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Scaffolding An estimated 2.3 million construction
workers, or 65 of the construction industry,
work on scaffolds frequently. Protecting these
workers from scaffold-related accidents would
prevent 4,500 injuries and 50 deaths every year,
at a savings for American employers of 90
million in workdays not lost. In a recent BLS
study, seventy-two percent of workers injured in
scaffold accidents attributed the accident either
to the planking or support giving way, or to the
employee slipping or being struck by a falling
object. All of these can be controlled by
compliance with OSHA standards.
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Read more about Scaffoldingby clicking
below.
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Legal Stuff

• Get To Know Your Activities Legal Counsel

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Some Hints and Tricks
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• Identify Those Individuals That Can Help
• Procurement Personnel
• Specification Writers.
• Tool Room Supervisors
• Training Personnel
• Engineering
• Union
• Let them be part of the effort and decisions
• They can work in their management structure more
  effectively than you.

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• Dont let the issue be about compliance or money.
  Stay above those arguments.
• Keep the issue safety of the worker for processes
  they perform.
• Acquire a set of equipment youve identified that
  is needed.
• Collect representative samples of bad stuff. Get
  or make a Roll-Out Lanyard
• Develop a short show and tell talk about the
  equipment.

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• Perform this talk at every opportunity to any
  group greater than one that will stand in one
  place long enough to hear it
• All Levels of Management
• Stand-up Safety Meetings
• Union Meetings
• Anywhere and Everywhere
• Encourage Workers and Supervisors to Call You.
• Make the set of equipment available to anyone
  that thinks they need it for a job or wants to
  try it.
• This ones hard, cause you have to be there.

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• Eventually (after lots and lots of work)
• You will not be able to handle the requests for
  help using the equipment you have.
• The result will be
• Workers will be complaining they cant get the
  stuff they need to do their job.
• Supervisors will begin complaining jobs are being
  delayed.

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• And Before You Know It
• Its All Your Fault!

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• Managers get involved. Allocate funding, ask the
  procurement personnel to buy the identified
  equipment Specifications are written, Training
  is developed (or external training identified).
• The group of individuals that you identified at
  the beginning all the sudden become folks with
  the answers in their organization.

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• At this point, ownership is taken by all the
  right people.
• There will always be naysayers.
• Once people believe that they CAN DO IT-
• THEY WILL DEMAND IT.

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• Then write your instruction
• and
• KEEP IT SIMPLE!

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Continue to Evaluate Your Program!

• You are guaranteed to find
• NEW AREAS OF CONCERN!

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Keep Yourself Up On.

• New or Specific Training Methods.
• New Equipment.
• Innovative Techniques.

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Thank You and Good Bye and Good Luck